BMW 325 325i 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Year: 2004 Codes Chassis Code: E46 Engine Code: M54B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Convertible Target...

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Mots clés: 2004 325 325i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

3 Series

Model Variant:

Year:

Codes

Chassis Code:

Engine Code:

M54B25

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Coupe/Convertible

Target Audience:

Enthusiasts, DIY mechanics, professional repair shops

Competitive Analysis

Key Competitors 2004:

Mercedes-Benz C-Class, Audi A4, Lexus IS300, Infiniti G35

Key Features

Vehicle Philosophy:

The Ultimate Driving Machine, balanced handling, refined performance

Manual Value Proposition:

Empowers owners with factory-accurate repair and maintenance knowledge

📋 Manual Details

Coverage Areas

Diagnostic Troubleshooting:

Extensive

Engine Mechanical:

Complete

Engine Management System:

Comprehensive

Transmission Systems:

Complete

Suspension Steering:

Complete

Brake Systems:

Complete

Electrical Systems:

Comprehensive

Body Interior:

Detailed

Climate Control:

Detailed

Body Electrical:

Comprehensive

Comfort Systems:

Detailed

Safety Systems:

Detailed

Maintenance Procedures:

Repair Procedures:

Wiring Diagrams:

Included

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission, Drivetrain

Chassis:

Suspension, Steering, Brakes

Electrical:

ECU, Sensors, Lighting, Power Distribution, Audio

Comfort And Convenience:

HVAC, Power Accessories, Seats

Body:

Exterior Panels, Interior Trim, Doors, Windows

Safety Features:

Airbags, Seatbelts, ABS, DSC

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks

Engine Repair:

Head gasket, piston rings, valve timing, component replacement

Transmission Service:

Fluid changes, seal replacements, clutch service (manual), valve body repair (automatic)

Brake Service:

Pad/rotor replacement, caliper overhaul, bleeding procedures

Electrical Diagnostics:

Component testing, sensor diagnosis, wiring harness repair

Troubleshooting Guides:

Fault code interpretation, symptom-based diagnosis

Assembly Disassembly:

Step-by-step instructions for component removal and installation

Body Repair:

Panel replacement, dent repair, trim installation

Technical Depth

Depth:

Factory-level detail for all repair and maintenance operations

Diagnostic Codes:

Covers OBD-II fault codes and BMW-specific codes

Torque Specifications:

All critical fastener torque values included

Clearances Tolerances:

Specified for key engine and mechanical components

📊 Manual Specifications

File Format

Type:

Searchability:

Searchable text for quick information retrieval

Print Quality

Resolution:

High-resolution, suitable for professional printing

Scalability:

Printable in entirety or specific sections

Binding Type

Binding:

Digital Download (Printable)

Paper Type

Recommendation:

Standard or heavy-weight paper for printing workshop copies

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-6, Naturally Aspirated

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84 mm x 75 mm

Compression Ratio:

10.2:1

Valve Train:

DOHC, 24 Valves, Double VANOS

Performance

Horsepower:

184 hp @ 6000 rpm

Torque:

237 Nm (175 lb-ft) @ 3500 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (Bosch Motronic ME9.2)

Fuel Type:

Premium Unleaded Gasoline (91 Octane Recommended)

Cooling System

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)

Lubrication System

Oil Capacity:

6.5 Liters (6.9 US Quarts)

Recommended Oil Viscosity:

SAE 0W-40 or 5W-30 (BMW LL-01 certified)

Ignition System

Spark Plugs:

NGK BKR6EQUP (or equivalent)

🔧 Transmission

Standard

Type:

5-Speed Manual (Getrag S5D 250G)

Optional

Type:

5-Speed Automatic (ZF 5HP19)

Features

Automatic Features:

Steptronic manual shift mode

Fluid Specifications Manual

Transmission Fluid:

GL-4 or GL-5 rated synthetic gear oil

Fluid Specifications Automatic

Transmission Fluid:

BMW ATF LT-3 (or equivalent Lifeguardfluid 5)

Gear Ratios Manual

First Gear:

4.235

Second Gear:

2.500

Third Gear:

1.556

Fourth Gear:

1.159

Fifth Gear:

0.853

Reverse:

3.727

📐 Dimensions

Exterior

Length:

4526 mm (178.2 in)

Width:

1739 mm (68.5 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2760 mm (108.7 in)

Weights

Curb Weight Manual:

1500 kg (3307 lbs)

Curb Weight Automatic:

1530 kg (3373 lbs)

Gross Vehicle Weight Rating:

1970 kg (4343 lbs)

Wheels Tires

Standard Wheel Size:

16 x 7.0 inch

Optional Wheel Size:

17 x 7.5 inch front, 17 x 8.0 inch rear

Standard Tire Size:

205/55R16

Optional Tire Size:

225/45R17 front, 245/40R17 rear

Bolt Pattern:

5x120

Center Bore:

72.5 mm

Lug Nut Size:

M14 x 1.5

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test:

5-Star (Driver & Passenger)

IIHS Side Impact Test:

Active Features

Traction Control:

Dynamic Stability Control (DSC)

Anti Lock Brakes:

Standard ABS

Braking Assist:

Optional, part of DSC system

Passive Features

Airbags:

Frontal, Side-impact, Optional Head Airbags

Seatbelts:

Pretensioners, Force Limiters

Child Seat Anchors:

LATCH system

💡 Technology Features

Infotainment

Head Unit Options:

BMW Business CD, BMW Professional CD, Optional Navigation System

Audio System:

Standard 6-speaker system, Optional Harman Kardon premium audio

Driver Assistance

Parking Assistance:

Optional Rear Park Distance Control (PDC)

Cruise Control:

Standard

Connectivity

Cellular Integration:

Optional BMW Assist telematics system

Auxiliary Input:

Not standard; aftermarket solutions available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable Service Interval (VSI) based on driving conditions, typically 10,000-15,000 miles or 1 year.

Air Filter Replacement:

Every 30,000 miles or as needed.

Cabin Filter Replacement:

Every 15,000-30,000 miles.

Spark Plug Replacement:

Every 60,000 miles for iridium plugs (NGK BKR6EQUP).

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles.

Brake Fluid Flush:

Every 2 years.

Fluid Specifications

Power Steering Fluid:

Pentosin CHF 11S or ZF-TE-ML 02K

Brake Fluid:

DOT 4

Known Issues

Ccv System Failure:

Cracked or clogged Crankcase Ventilation (CCV) system leading to oil consumption and rough idle.

Oil Pan Gasket Leaks:

Common leaks from valve cover gaskets and oil pan gasket due to age and material degradation.

Cooling System Failures:

Plastic expansion tank cracks, water pump failure, thermostat issues.

ABS Wheel Speed Sensor Failure:

Common failure leading to ABS and DSC warning lights.

Interior Plastic Degradation:

Sticky interior plastics and crumbling trim pieces.

📚 Vehicle History

Brand Heritage

Brand Identity:

Bayerische Motoren Werke AG (BMW), renowned for performance, engineering, and luxury.

Model Evolution

E46 Generation Introduction:

The E46 generation of the 3 Series was introduced in 1998 (for the 1999 model year in Europe, 2000 in North America) and ran until 2006.

325I Positioning E46:

The 325i served as a mid-range model in the E46 lineup, slotting above the 323i and below the 330i, offering a balance of performance and value.

Engine Transition:

The M54B25 engine replaced the M52TU B25 in 2001, featuring an aluminum block, improved VANOS, and higher output.

Production

Production Years E46 325I:

2001-2005

Manufacturing Locations:

Germany (Dingolfing, Munich), South Africa, USA (Spartanburg)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E46 3 Series (various models including 325i) was a frequent recipient of Car and Driver's 10Best awards during its production run.

Road And Track Best Handling Car:

Consistently praised for its class-leading handling and driving dynamics by automotive journalists.

Certifications

Engine Designation:

Ward's 10 Best Engines recognition for the M54 engine family.